Films and bags with visually distinct regions and methods of making the same

Abstract

One or more implementations of a multi-layer film include a first substantially un-pigmented layer non-continuously bonded to a second pigmented layer. The multi-layer film includes an unexpected appearance differing from the appearance of the pigmented layer. In one or more embodiments, the multi-layer film includes a metallic appearance despite the pigmented layer being devoid of metallic pigment. The multi-layer film also includes areas that are visually distinct from areas of the film with the unexpected appearance. The visually-distinct areas comprise areas in which the first substantially un-pigmented layer non-continuously bonded is in intimate contact with the second pigmented layer. The visually-distinct areas have the appearance of the pigmented layer. One or more implementations also include methods of making multi-layer films and bags with an unexpected appearance and visually-distinct areas.

We claim: 
     
       1. A method of producing a multi-layer film with an unexpected appearance, comprising:
 non-continuously bonding a first thermoplastic layer having a first appearance to a second pigmented thermoplastic layer having a second appearance by creating:
 a plurality of bonds securing the first thermoplastic layer to the second pigmented thermoplastic layer by bringing one or more areas of the first thermoplastic layer into intimate contact with the second pigmented thermoplastic layer thereby causing an appearance of the one or more areas of the first thermoplastic layer, when viewed from the first thermoplastic layer side of the multi-layer film, to have the second appearance of the second pigmented thermoplastic layer; and 
 a plurality of un-bonded areas in which the first thermoplastic layer and the second pigmented thermoplastic layer are un-bonded and separated, wherein when viewed from the first thermoplastic layer side of the multi-layer film, the plurality of un-bonded areas having a third appearance differing from the first appearance of the first thermoplastic layer and from the second appearance of the second pigmented thermoplastic layer. 
 
 
     
     
       2. The method as recited in  claim 1 , wherein creating the plurality of bonds securing the first thermoplastic layer to the second pigmented thermoplastic layer by bringing one or more areas of the first thermoplastic layer into intimate contact with the second pigmented thermoplastic layer comprises heat sealing portions of the first thermoplastic layer to the second pigmented thermoplastic layer. 
     
     
       3. The method as recited in  claim 2 , wherein creating the plurality of bonds securing the first thermoplastic layer to the second pigmented thermoplastic layer by bringing one or more areas of the first thermoplastic layer into intimate contact with the second pigmented thermoplastic layer further comprises forming a plurality of pressure bonds. 
     
     
       4. The method as recited in  claim 3 , wherein forming the plurality of pressure bonds comprises forming one or more of ring rolling bonds or structural-elastic-like-film (SELFing) bonds. 
     
     
       5. The method as recited in  claim 1 , further comprising:
 incrementally stretching the first thermoplastic layer by passing the first thermoplastic layer through a first pair of intermeshing ring rolls; and 
 non-continuously bonding the second pigmented thermoplastic layer to the first thermoplastic layer by passing the second pigmented thermoplastic layer and the first thermoplastic layer together through a second pair of intermeshing ring rolls. 
 
     
     
       6. The method as recited in  claim 1 , wherein the first thermoplastic layer is non-pigmented and the first appearance is a clear or transparent appearance. 
     
     
       7. The method as recited in  claim 6 , wherein the second appearance is color created by a pigment in the second pigmented thermoplastic layer. 
     
     
       8. The method as recited in  claim 7 , wherein the third appearance is a second color differing from the color of the second appearance and wherein the multi-layer film is devoid of a pigment of the second color. 
     
     
       9. The method as recited in  claim 8 , wherein the color of the second appearance is a non-metallic color and the second color is a metallic color. 
     
     
       10. The method as recited in  claim 8 , wherein the color of the second appearance is black and the second color is grey. 
     
     
       11. A method of producing a multi-layer film with an unexpected appearance, comprising:
 non-continuously bonding a first substantially un-pigmented thermoplastic film layer to a second pigmented thermoplastic film layer, wherein:
 the first substantially un-pigmented thermoplastic film layer is transparent or translucent; 
 the second pigmented thermoplastic film layer comprising a pigment, the second pigmented thermoplastic film layer having a first color created by the pigment; 
 non-continuously bonding the first substantially un-pigmented thermoplastic film layer to the second pigmented thermoplastic film layer comprises forming:
 a plurality of non-continuous bonds securing the first substantially un-pigmented thermoplastic film layer in intimate contact to the second pigmented thermoplastic film layer; 
 a plurality of heat seals securing the first substantially un-pigmented thermoplastic film layer to the second pigmented thermoplastic film layer; and 
 a plurality of un-bonded areas in which the first substantially un-pigmented thermoplastic film layer the second pigmented thermoplastic film layer are not bonded to each other and separated by a gap; 
 
 the un-bonded areas, when viewed from the first substantially un-pigmented thermoplastic film layer side of the multi-layer film, have a second color differing from the first color; and 
 wherein the heat seals, when viewed from the first substantially un-pigmented thermoplastic film layer side of the multi-layer film, are the first color. 
 
 
     
     
       12. The method as recited in  claim 11 , further comprising forming a multi-layered bag with sidewalls comprising the multi-layer film. 
     
     
       13. The method as recited in  claim 12 , wherein forming the multi-layered bag comprises configuring the first substantially un-pigmented thermoplastic film layer as an outside layer of the sidewalls. 
     
     
       14. The method as recited in  claim 13 , wherein forming the plurality of heat seals comprises forming side seals. 
     
     
       15. The method as recited in  claim 11 , wherein forming the plurality of non-continuous bonds comprises passing the first substantially un-pigmented thermoplastic film layer and the second pigmented thermoplastic film layer together through a pair of ring rolls. 
     
     
       16. The method as recited in  claim 11 , wherein forming the plurality of non-continuous bonds comprises passing the first substantially un-pigmented thermoplastic film layer and the second pigmented thermoplastic film layer together through a pair of structural-elastic-like-film (SELFing) rolls. 
     
     
       17. The method as recited in  claim 11 , wherein:
 the first color is black; 
 the second color is a metallic silver; and 
 the first substantially un-pigmented thermoplastic film layer is transparent. 
 
     
     
       18. The method as recited in  claim 11 , wherein:
 the first color is black; 
 the second color is grey; and 
 the first substantially un-pigmented thermoplastic film layer is translucent. 
 
     
     
       19. The method as recited in  claim 11 , wherein:
 the first substantially un-pigmented thermoplastic film layer comprises less than two percent by concentration of pigment and is transparent or translucent; and 
 the second pigmented thermoplastic film layer comprises between three percent and six percent by concentration of pigment and is opaque. 
 
     
     
       20. The method as recited in  claim 11 , further comprising forming a plurality of alternating thicker ribs and thinner webs in the first substantially un-pigmented thermoplastic film layer.